Battery management systems and methods to use the same to obtain battery shock and/or rollover data

ABSTRACT

Battery management systems and methods for using the same to obtain battery shock and/or rollover data. An exemplary battery management system of the present disclosure comprises an accelerometer configured to obtain acceleration data, a microcontroller operably connected to the accelerometer and configured to receive the acceleration data from the accelerometer, and a data storage medium in communication with the microcontroller, the data storage medium configured to store the acceleration data therein, wherein when the battery management system is in communication with a battery, the accelerometer can obtain the acceleration data relating to the battery, and the microcontroller can operate to disconnect the battery from a load connected thereto should the acceleration data meet or exceed a threshold limit.

PRIORITY

The present application is related to, and claims the priority benefitof, U.S. Provisional Patent Application Ser. No. 62/448,154, filed Jan.19, 2017, the contents of which are incorporated herein directly and byreference in their entirety.

BACKGROUND

Large battery systems are used in environments where high shock levelscan be dangerous to the battery operation. In addition, due to the heavyweight of certain battery systems, they can be mishandled/dropped duringtransportation which can render the battery unsafe for usage. Duringhandling the batteries may be rolled over which can also damage theinternal components of the battery making them unsafe for operation. Theissues are compounded with the high energy potential of lithium batterysystems.

Current mechanisms to detect shock or rollover include the use ofrollover or shock gauges attached to the exterior surface of the batteryor its housing for visible notification. However, these gauges cannotnot prevent usage of the battery, and they require visual inspection todetermine if the battery had been damaged. Said gauges also do notcollect data over time to determine if improper operational environmentfor the battery was being utilized unsafely.

In view of the foregoing, a system for determining the extent of shockand/or rollover of a battery that can not only store said data to beaccessed in the future, but also configured to disable said potentiallydamaged or dangerous battery, would be well received in the marketplace.

BRIEF SUMMARY

The present disclosure includes disclosure of a battery managementsystem, comprising an accelerometer configured to obtain accelerationdata; a microcontroller operably connected to the accelerometer andconfigured to receive the acceleration data from the accelerometer; anda data storage medium in communication with the microcontroller, thedata storage medium configured to store the acceleration data therein;wherein when the battery management system is in communication with abattery, the battery management system can obtain the acceleration datarelating to the battery and disconnect the battery from a load connectedthereto should the acceleration data meet or exceed a threshold limit.

The present disclosure includes disclosure of a battery managementsystem, wherein the accelerometer data is indicative of g forcesexperienced by the battery.

The present disclosure includes disclosure of a battery managementsystem, wherein the accelerometer data is indicative of a degree ofrollover or tilt experienced by the battery.

The present disclosure includes disclosure of a battery managementsystem, configured to be connected to a computer, whereby theacceleration data from the data storage medium can be transferred fromthe battery management system to the computer.

The present disclosure includes disclosure of a battery managementsystem, comprising an accelerometer configured to obtain accelerationdata; a microcontroller operably connected to the accelerometer andconfigured to receive the acceleration data from the accelerometer; anda data storage medium in communication with the microcontroller, thedata storage medium configured to store the acceleration data therein;wherein when the battery management system is in communication with abattery, the accelerometer can obtain the acceleration data relating tothe battery, and the microcontroller can operate to disconnect thebattery from a load connected thereto should the acceleration data meetor exceed a threshold limit.

The present disclosure includes disclosure of a battery managementsystem, wherein the accelerometer data is indicative of g forcesexperienced by the battery.

The present disclosure includes disclosure of a battery managementsystem, wherein the accelerometer data is indicative of a degree ofrollover or tilt experienced by the battery.

The present disclosure includes disclosure of a battery managementsystem, configured for connection to a computer, whereby theacceleration data from the data storage medium can be transferred fromthe battery management system to the computer and accessed by thecomputer.

The present disclosure includes disclosure of a battery managementsystem, further comprising the battery in communication with themicrocontroller.

The present disclosure includes disclosure of a battery managementsystem, wherein the data storage medium comprises flash memory.

The present disclosure includes disclosure of a battery managementsystem, wherein the acceleration data is indicative of three-axisinformation, and wherein the microcontroller can operate to disconnectthe battery from a load connected thereto should the acceleration dataof at least one axis of the three-axis information meet or exceed athreshold limit.

The present disclosure includes disclosure of a battery managementsystem, wherein the acceleration data is indicative of a free fall ofthe battery, and wherein the microcontroller can operate to disconnectthe battery from a load connected thereto due to the indication of thefree fall of the battery.

The present disclosure includes disclosure of a battery managementsystem, wherein the battery is connected to the load using a switch, andwherein the microcontroller is configured to operate the switch todisconnect the battery from the load.

The present disclosure includes disclosure of a battery managementsystem, further comprising a display in communication with themicrocontroller, the display configured to display the accelerationdata.

The present disclosure includes disclosure of a battery managementsystem, further comprising a power supply connected to themicrocontroller, configured to provide power to the microcontroller.

The present disclosure includes disclosure of a battery managementsystem, comprising an accelerometer configured to obtain accelerationdata; a microcontroller operably connected to the accelerometer andconfigured to receive the acceleration data from the accelerometer; adata storage medium in communication with the microcontroller, the datastorage medium configured to store the acceleration data therein; adisplay in communication with the microcontroller, the displayconfigured to display the acceleration data; and a power supplyconnected to the microcontroller, configured to provide power to themicrocontroller; wherein when the battery management system is incommunication with a battery, the accelerometer can obtain theacceleration data relating to the battery, and the microcontroller canoperate to disconnect the battery from a load connected thereto shouldthe acceleration data meet or exceed a threshold limit.

The present disclosure includes disclosure of a battery managementsystem, wherein the acceleration data is indicative of three-axisinformation, and wherein the microcontroller can operate to disconnectthe battery from a load connected thereto should the acceleration dataof at least one axis of the three-axis information meet or exceed athreshold limit.

The present disclosure includes disclosure of a battery managementsystem, wherein the battery is connected to the load using a switch, andwherein the microcontroller is configured to operate the switch todisconnect the battery from the load.

The present disclosure includes disclosure of a method of using abattery management system, comprising positioning a battery managementsystem in communication with a battery connected to a load, the batterymanagement system comprising an accelerometer configured to obtainacceleration data from the battery; a microcontroller operably connectedto the accelerometer and configured to receive the acceleration datafrom the accelerometer; and a data storage medium in communication withthe microcontroller, the data storage medium configured to store theacceleration data therein; and operating the accelerometer to obtain theacceleration data and operating the microcontroller to receive theacceleration data from the accelerometer.

The present disclosure includes disclosure of a method of using abattery management system, further comprising the step of operating themicrocontroller to disconnect the battery from the load due to theacceleration data meeting or exceeding a threshold limit.

The present disclosure includes disclosure of a method of using abattery management system, further comprising the step of operating themicrocontroller to reconnect the battery to the load.

The present disclosure includes disclosure of a method of using abattery management system, wherein the acceleration data comprises adetected amount of gravitational force experienced by the battery.

The present disclosure includes disclosure of a method of using abattery management system, wherein the acceleration data comprises adetected degree of tilt or rollover experienced by the battery.

The present disclosure includes disclosure of a method of using abattery management system, wherein the acceleration data includes datarelating to a number of instances that the battery meets or exceeds athreshold limit of acceleration.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosed embodiments and other features, advantages, anddisclosures contained herein, and the matter of attaining them, willbecome apparent and the present disclosure will be better understood byreference to the following description of various exemplary embodimentsof the present disclosure taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 shows a block component diagram of a battery management systemconnected to a battery, according to an exemplary embodiment of thepresent disclosure;

FIG. 2 shows a flowchart of steps relating to obtaining accelerometerdata, according to an exemplary embodiment of the present disclosure;

FIG. 3 shows a flowchart of steps relating to disconnecting a batteryfrom a load based on accelerometer data, according to an exemplaryembodiment of the present disclosure; and

FIG. 4 shows a flowchart of steps relating to obtaining and storingaccelerometer data, according to an exemplary embodiment of the presentdisclosure.

As such, an overview of the features, functions and/or configurations ofthe components depicted in the various figures will now be presented. Itshould be appreciated that not all of the features of the components ofthe figures are necessarily described and some of these non-discussedfeatures (as well as discussed features) are inherent from the figuresthemselves. Other non-discussed features may be inherent in componentgeometry and/or configuration. Furthermore, wherever feasible andconvenient, like reference numerals are used in the figures and thedescription to refer to the same or like parts or steps. The figures arein a simplified form and not to precise scale.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of thepresent disclosure, reference will now be made to the embodimentsillustrated in the drawings, and specific language will be used todescribe the same. It will nevertheless be understood that no limitationof the scope of this disclosure is thereby intended.

Exemplary battery management systems 100 of the present disclosure, suchas shown in FIG. 1 , comprise an accelerometer 102 configured to monitora physical environment of a battery 150 in communication therewith.Accelerometer 102 is in communication with (directly or indirectlycoupled to) a microcontroller 104 (namely a processor ormicroprocessor), configured to monitor the battery environment forvarious shock levels or acceleration, as determined by accelerometer102, which can indicate that battery 150 may have been mishandled, suchas being dropped and/or rolled over.

Microcontroller 104 can use acceleration data obtained fromaccelerometer 102 to determine if improper operation or handling ofbattery 150 has occurred. Should the acceleration data levels exceed anestablished safety threshold, battery management system 100 can provideerror conditions/information to a user of battery management system 100via one or more messages/indications, as referenced in further detailherein.

Battery management systems 100, in various embodiments, further comprisea data storage medium 106, such as flash memory. Exemplary data storagemedia 106 of the present disclosure may include, but are not limited to,universal serial bus (USB) drives (“thumb” drives), secure digital (SD)cards, SD high capacity (SDHC) cards, SD extended capacity (SDXC) cards,miniSD cards, microSD cards, compact flash (CF) cards, XQD cards,non-volatile flash memory, electrically erasable programmable read-onlymemory (EEPROMS), and the like.

In the event microcontroller 104 determines that battery managementsystem 100 has been mishandled, battery management system 100 will shutdown the power output of battery 150 to prevent unsafe operations.

Microcontroller 104 is configured to continuously read the three-axis(x, y, and z axis) g force information from accelerometer 102, and isconfigured to transmit said accelerometer data to data storage medium106, such as a SD card. In at least some battery management system 100embodiments, microcontroller 104 is also configured to transmit saidaccelerometer data to an external computer 125, such as via USB, acabled connection, controller area network (CAN) bus (including serialmessages), wirelessly (through wi-fi, IEEE 802.11, Bluetooth, and thelike), etc., whereby microcontroller 104 can be connected directly orindirectly to computer 125 to transmit said data. Data storage medium106 can also be removed from battery management system 100 and connecteddirectly or indirectly to computer 125, as may be desired. It is notedthat a computer 125 is not required in order for a battery managementsystem 100 of the present disclosure to operate as desired.

Accelerometers 102 of the present disclosure are also configured togenerate interrupts for a free fall detection, such as when one or morerespective axis g values exceed a configured threshold limit. Whenmicrocontroller 104 senses the interrupt, it can operate to disconnectthe load from the battery 150. Microcontrollers 104 can also analyze andcheck the accelerometer data against pre-defined shock and rolloverthresholds, and log the status and/or number of occurrences in datastorage medium 106.

FIG. 1 shows an exemplary battery management system 100 of the presentdisclosure and how various components thereof couple to and/or otherwisecommunicate with other portions of battery management system 100 and anexemplary battery 150. For example, and as shown therein, an exemplarybattery management system 100 comprises an accelerometer 102 coupled toor otherwise in communication with a microcontroller 104.Microcontroller 104 is also coupled to or otherwise in communicationwith a data storage medium 106, such as a SD card or other data storagemedium 106. Battery management system 100 is configured to be coupled toa battery 150, such as shown in FIG. 1 , so to control whether or notbattery 150 is effectively connected to a load 175, such as, forexample, by way of controlling operation of a switch 160 effectivelycoupled to battery 150 and load 175. For example, and shouldmicrocontroller 104 instruct switch 160 (or otherwise permit switch 160)to be or remain closed, battery 150 would be effectively connected toload 175 so to provide power to load 175 so that load 175 can at leastpartially operate from power from battery 150. Should microcontroller104 instruct switch 160 (or otherwise permit switch 160) to be or remainopen, battery 150 would be effectively disconnected from load 175 sothat power from battery 150 is not provided to load 175. As shown inFIG. 1 , various components of battery management system 100 can beconnected to or otherwise be in communication with other components ofbattery management system 100 and/or external components, such ascomputer 125, battery 150, switch 160, etc., via one or moreconnection/communication mechanisms, such as inter-integrated circuits(I2Cs), serial peripheral interfaces (SPIs), board relays (BD-RLYs), USBconnectors, etc. Said connection/communication mechanisms are referredto herein as connections 130, and can be unidirectional, such as by wayof accelerometer 102 transmitting acceleration data to microcontroller104 (or microcontroller 104 receiving transmission data fromaccelerometer 102), or bidirectional, such as microcontroller 104providing information/data to computer 125 or data storage medium 106and computer 125 or data storage medium 106 providing information/datato microcontroller 104. Software, namely computer instructionsexecutable by microcontroller 104, could be stored on data storagemedium 106 or at another location, and can contain the variousinstructions/parameters in connection with the determination as towhether or not to connect and/or disconnect battery 150 from load 175,whether or not to operate switch 160, whether or not to saveaccelerometer data from accelerometer 102 within data storage medium 106or computer 125, and the like, in connection with operation ofmicrocontroller 104 as referenced herein.

FIG. 2 depicts steps of an exemplary flowchart depicting exemplary stepsof operation of components of an exemplary battery management system 100of the present disclosure relating to the process of logging axisparameters (obtaining accelerometer data from accelerometer 102 andstoring the same in data storage medium 106). As shown therein, variouscomponents of battery management system 100 could be initialized, suchas accelerometer 102, microcontroller 104, various connectors/circuits,etc. (such as, for example, the USB connection, the I2Cs, etc.,referenced in FIG. 2 ), so that accelerometer 102 is active/operationaland able to obtain accelerometer data, and so that microcontroller 104is active/operational and able to obtain accelerometer data fromaccelerometer 102, direct storage of said data in data storage medium106, direct opening and/or closing of switch 160, and/or directtransmission of said data to computer 125. Accelerometer data can beobtained at various time intervals as may be desired, and said data canbe stored within data storage medium 106 and/or transferred to computer125 at intervals as may be desired. In addition, calculations can beperformed using microcontroller 104, based upon the acceleration dataobtained from accelerometer 102, to determine a potential extent,degree, or level of tilt, shock, and/or rollover of battery 150, wherebysaid calculations generate calculated acceleration data that can also bestored in data storage medium and be used by microcontroller 104 todetermine whether or not battery 150 should be or remain connected toload 175.

As referenced herein, accelerometer 102 is configured to obtainaccelerometer data in connection with a handling status of battery 150.For example, accelerometers 102, in various embodiments, are configuredto determine whether or not a battery 150 has been tilted (and to whatdegree of tilt), experienced shock (a force against battery 150) and towhat extent/degree, rolled over, and/or whether or not battery 150 hasfallen, which can be determined based on potential forces/impacts and/oracceleration data, in various axes (x-, y-, and/or z-, as referencedherein), such that potential crash or other damage (including vibrationdamage) can be identified/determined. Said data can be obtained duringtransport of battery 150 and/or during use of battery 150, such as whenbattery 150 is connected to a load 175, and can be used to determine ifbattery 150 has been mishandled, inappropriately/improperly transported,damaged, etc., so that use of battery 150 can be discontinued ifnecessary. For example, accelerometer 102 can obtain acceleration dataduring transport (such as by use of a fork truck or other transportmechanism) and/or during use, as referenced herein. Said accelerationdata could identify potential future concerns with battery 150, such asprolonged vibration, shock, etc., so that battery 150 can bedisconnected from load 175 prior to battery 150 becoming potentiallydangerous to use.

FIG. 3 depicts steps of an exemplary flowchart depicting exemplary stepsof operation of components of an exemplary battery management system 100of the present disclosure relating to free fall detection. Shouldbattery 150 experience a level of tilt and/or shock exceeding levels setwithin battery management system 100 (whereby said levels are generallyrelated to safe operation of battery 150, and when said levels are metand/or exceeded, battery 150 may no longer be safely operational),microcontroller 104 can instruct switch 160 to open or otherwise causebattery 150 to effectively be disconnected form load 175. Data relatingto said instruction can be stored in data storage medium 106 and/orultimately transmitted to computer 125. A user/operator, upon receipt ofsaid instruction data (causing battery 150 to be effectivelydisconnected from load 175), can then decide whether or not to reconnectbattery 150 to load 175. Said data can also serve as a warning to auser/operator of battery 150 that battery 150 may have been compromiseddue to shock and/or rollover and that battery 150 may therefore beunsafe for use. In various embodiments of battery management systems 100of the present disclosure comprising a display or indicator 180configured to display or indicate a status of battery connectivity, suchas a display screen, one or more lights, etc., said display or indicator180 could display or indicate an operative status of battery 150 (suchthat a load 175 is operatively connected to battery 150, such as whenswitch 160 is closed) and/or a disconnected status of battery 150 (suchthat load 175 is no longer operatively connected to battery 150, such aswhen switch 160 is open). Display or indicator 180 would be operativelyconnected to at least one component of battery management system 100,such as, for example, accelerometer 102, microcontroller 104, and/orstorage medium 106.

FIG. 4 depicts steps of an exemplary flowchart depicting exemplary stepsof operation of components of an exemplary battery management system 100of the present disclosure as relating to shock thresholds and rolloverthresholds and logging data relating to the same. For example, a shockthreshold may be a detected amount of gravitational force experienced bybattery 150, and a rollover threshold may be a detected degree of tiltor rollover experienced by battery 150. As shown therein, exemplarybattery management systems 100 of the present disclosure are configuredto not only obtain data relating to whether or not a threshold amount ofshock (left side of FIG. 4 ) and/or rollover (right side of FIG. 4 ) ofbattery 150 has been met or exceeded, but also how many times thethreshold has been met or exceeded. The number of times (and associateddate, time, and or extent of shock or degree of rollover) can beobtained by accelerometer 102 and stored within data storage medium 106as desired, whereby said data can be stored within data storage medium106 at the direction of microcontroller 104 and retrieved from datastorage medium 106 at the direction of microcontroller 104, as may bedesired.

The present disclosure also includes disclosure of relatingaccelerometer data obtained from accelerometer 102 to a warranty orguarantee of battery 150. For example, a battery 150 could have awarranty or guarantee that is based on proper use and would be voided ifthe battery 150 was mishandled. A battery management system 100 of thepresent disclosure can be used to monitor levels of shock and/orrollover (tilt and the degree of the same) using accelerometer 102, andshould accelerometer 102 detect high and or repeated levels of shockand/or rollover, that acceleration data can be the basis of voiding awarranty of guarantee of the battery 150 being monitored by batterymanagement system 100.

Battery management systems 100 of the present disclosure can be enclosedwithin a housing 110, such as shown in FIG. 1 , whereby variouscomponents of battery management systems 100 can be enclosed therein asmay be desired. Various components of battery management systems 100,such as accelerometer 102, microcontroller 104, and/or storage medium106 can be powered by a power supply 115 (such as a battery) connectedthereto, such as shown in FIG. 1 , and/or powered by a battery 150connected thereto that is being monitored by said battery managementsystem 100.

While various embodiments of battery management systems and methods forusing the same to obtain battery shock and/or rollover data have beendescribed in considerable detail herein, the embodiments are merelyoffered as non-limiting examples of the disclosure described herein. Itwill therefore be understood that various changes and modifications maybe made, and equivalents may be substituted for elements thereof,without departing from the scope of the present disclosure. The presentdisclosure is not intended to be exhaustive or limiting with respect tothe content thereof.

Further, in describing representative embodiments, the presentdisclosure may have presented a method and/or a process as a particularsequence of steps. However, to the extent that the method or processdoes not rely on the particular order of steps set forth therein, themethod or process should not be limited to the particular sequence ofsteps described, as other sequences of steps may be possible. Therefore,the particular order of the steps disclosed herein should not beconstrued as limitations of the present disclosure. In addition,disclosure directed to a method and/or process should not be limited tothe performance of their steps in the order written. Such sequences maybe varied and still remain within the scope of the present disclosure.

The invention claimed is:
 1. A battery management system, comprising: anaccelerometer configured to obtain acceleration data, wherein theacceleration data is used to calculate a degree of tilt or shockexperienced by a battery; a microcontroller operably connected to theaccelerometer and configured to receive the acceleration data from theaccelerometer; and a data storage medium in communication with themicrocontroller, the data storage medium configured to store theacceleration data therein; wherein when the battery management system isin communication with the battery, the accelerometer obtains theacceleration data relating to the battery; and wherein when theacceleration data indicates the degree of tilt or shock of the batterymeets or exceeds a threshold limit of degree of tilt or shock, themicrocontroller operates to disconnect the battery from a load and logsthe acceleration data, a status, the degree of tilt or shock, and anumber of instances meeting or exceeding said threshold limit of degreeof tilt or shock in the data storage medium.
 2. The battery managementsystem of claim 1, wherein the acceleration data is indicative of gforces experienced by the battery.
 3. The battery management system ofclaim 1, configured for connection to a computer, whereby theacceleration data from the data storage medium can be transferred fromthe battery management system to the computer and accessed by thecomputer.
 4. The battery management system of claim 1, furthercomprising: the battery in communication with the microcontroller. 5.The battery management system of claim 1, wherein the data storagemedium comprises flash memory.
 6. The battery management system of claim1, wherein the acceleration data is indicative of a free fall of thebattery, and wherein the microcontroller can operate to disconnect thebattery from a load connected thereto due to the indication of the freefall of the battery.
 7. The battery management system of claim 4,wherein the battery is connected to the load using a switch, and whereinthe microcontroller is configured to operate the switch to disconnectthe battery from the load.
 8. The battery management system of claim 1,further comprising: a display in communication with the microcontroller,the display configured to display the acceleration data.
 9. The batterymanagement system of claim 1, further comprising: a power supplyconnected to the microcontroller, configured to provide power to themicrocontroller.
 10. A battery management system, comprising: anaccelerometer configured to obtain acceleration data, wherein theacceleration data is indicative of a degree of tilt or shock of abattery connected to a load; a microcontroller operably connected to theaccelerometer and configured to receive the acceleration data from theaccelerometer; a data storage medium in communication with themicrocontroller, the data storage medium configured to store theacceleration data therein; a display in communication with themicrocontroller, the display configured to display the accelerationdata; and a power supply connected to the microcontroller, configured toprovide power to the microcontroller; wherein the accelerometer obtainsthe acceleration data, and the acceleration data is used to determine ifbattery use should be discontinued; wherein when the battery managementsystem is in communication with the battery, the accelerometer obtainsthe acceleration data relating to the battery; and whereupon themicrocontroller operates to disconnect the battery from the load shouldthe acceleration data indicate the degree of tilt or shock of thebattery meets or exceeds a threshold limit of degree of tilt or shock ofthe battery and the microcontroller logs the acceleration data, astatus, and a number of instances meeting or exceeding said thresholdlimit in the data storage medium.
 11. The battery management system ofclaim 10, wherein the battery is connected to the load using a switch,and wherein the microcontroller is configured to operate the switch todisconnect the battery from the load.
 12. A method of using a batterymanagement system, comprising: positioning a battery management systemin communication with a battery connected to a load, the batterymanagement system comprising: an accelerometer configured to obtainacceleration data from the battery, wherein the acceleration data isindicative of a degree of tilt or shock of a battery; a microcontrolleroperably connected to the accelerometer and configured to receive theacceleration data from the accelerometer; and a data storage medium incommunication with the microcontroller, the data storage mediumconfigured to store the acceleration data therein; operating theaccelerometer to obtain the acceleration data and operating themicrocontroller to receive the acceleration data from the accelerometer;generating calculated acceleration data by calculating the degree oftilt or shock experienced by the battery based upon the accelerationdata; using the calculated acceleration data to determine the batteryshould not be connected to the load; operating the microcontroller todisconnect the battery from the load; and checking the acceleration dataagainst tilt or shock threshold limits and logging the accelerationdata, a status, and a number of occurrences where the acceleration datameets or exceeds the tilt or shock threshold limits in the data storagemedium.
 13. The method of claim 12, further comprising the step of:operating the microcontroller to reconnect the battery to the load. 14.The method of claim 12, wherein the acceleration data comprises adetected amount of gravitational force experienced by the battery. 15.The method of claim 12, wherein the acceleration data includes datarelating to a number of instances that the battery meets or exceeds athreshold limit of acceleration.